Download Optimizer of fuel mixture ratio SD-04 User manual - Sds

Optimizer of fuel mixture ratio
SD-04
User manual
www.sds-max.com.ua
Contents
1
2
3
3.1
3.2
3.3
4
4.1
4.2
4.2.1
4.2.2
4.3
5
5.1
5.1.1
5.1.2
5.2
5.3
5.3.1
5.3.2
5.4
5.5
6
7
Completeness
Operation concept and purpose
Installation of the optimizer
Connection to the oxygen sensor (oxygen sensor)
Connection to MAF, MAP
Connection to Common Rail diesel engine
Connection to computer, software
Requirements for personal computer
Examination of software
Output on graph
Window “Settings” - description of settings
First actuation
Settings of the optimizer
Description of simple and 3-D correction
Simple correction mode
3-D correction mode
Setting the correct display of the fuel consumption
Mode of oxygen sensor “Emulator” inputs
Training the emulator
Setting up the emulator
Mode of oxygen sensor “MAF(P)” inputs
Settings with diesel
Possible difficulties and their elimination
Warranty
Page.
3
4
5
5
9
11
12
12
13
15
16
20
21
21
22
23
25
26
26
26
28
29
30
32
1.
Completeness
O. No.
Name
Quantity
1
Electronics module
1
2
User manual
1
3
Quick connector
8
4
Set of wires
1
5
Disc with software
1
6
Notes
2.
Operation concept and purpose
The purpose of the optimizer is to correct the indicators of the engine. It can be used as an
alternative to CHIP tuning.
The control of fuel supply is performed by correction of the signals from the oxygen
sensors (oxygen sensor) and mass air flow sensor (MAF, MAP) according to the program that
the user defines.
The optimizer comes with software that allows to connect it to the computer, to read and
write all parameters in real time, to read fuel consumption, to make adjustments without stopping
the engine. It provides data output on the diagrams. It is possible to save and record the 3dimensional table of correction of sensors (MAF, MAP).
The optimizer has two modes: “simple” and “advanced”.
When user chooses simple mode, he needs to specify a few basic parameters that affect the
correction. In this mode, the degree of correction increases with the increase of fuel
consumption. When a certain threshold rotational rate is increased, the degree of correction can
be reduced (user-defined).
When user chooses advanced mode, he can draw up a detailed map of the signal correction
depending on the fuel injection time and the rotational rate of the crankshaft separately for
oxygen sensor and MAF, MAP.
To avoid errors in the electronic control unit (ECU) of the vehicle, the correction of signals
from the oxygen sensors is performed after a certain time after ignition (user-defined).
The device can work with MAF, MAP that have both analog and pulse output.
The optimizer supports broadband and zirconium oxygen sensors (oxygen sensor).
Accurate measurement, maintenance and regulation of oxygen sensor values (composition of airfuel mixture) are possible, when broadband sensors are used.
For normal operation of the device, the oxygen sensor must be in good condition.
The device can emulate the work of the 2nd oxygen sensor even at the absence of the
catalytic converter and the oxygen sensor itself.
3.
Installation of the optimizer
The optimizer should be installed in a place protected from the effects of high temperatures
and moisture.
If the optimizer is used in the system SuperAquaCar, it is recommended to install the
optimizer after electrolysis cell is set up and tested.
Power the system up. The black wire must be connected to the body of ECU (control unit)
or to the body of the car near the ECU. The power supply of 12 volts can be taken from the
vehicle's fuse panel or feed wire of nozzle. If you connect it through the fuse block, you need to
find a fuse, on which there is voltage only when the ignition is on, and then connect the red wire
to this fuse.
The blue wire is connected to the control (negative) wire of the nozzle.
3.1.
Connection to the oxygen sensor (oxygen sensor)
If you have zirconium oxygen sensor, the best result is usually achieved in the
“optimizer” mode. In the “optimizer” mode, oxygen sensor is connected after the process of
self-instruction.
To connect oxygen sensors, you need to find two signal wires of oxygen sensor by
measuring the voltage on the wires connected to the sensor at fully warmed up and running
engine.
For zirconium sensor, the positive signal wire is that wire, the voltage of which varies from
about 0.1 to 0.9 (sometimes from 0.5 to 1.5 Volts) as to the chassis of the vehicle with intervals
of 0.5 - 2 seconds when the engine is at idle. Usually the blue wire (+) and white (-) one belong
to the signal wire. The voltage at the negative signal wire is typically 0 Volt. In some cases, the
voltage on this wire can be up to 0,5 Volt. The two wires of the same color are used to power
the heater of the oxygen sensor. The absence of voltage with above mentioned parameters
indicates a possible malfunction of zirconium oxygen sensor.
For wideband oxygen sensor, the signal wires are those wires, the voltage of which is
normally 2.2.... 3.3 Volts.
The optimizer is connected to two signal wires of the oxygen sensor with the special
“quick connectors” (see Fig. 3.8.).
There are three ways to connect zirconium oxygen sensor:
1. The most proper regulation of a mixture using zirconium oxygen sensor is in the
“Emulator” mode. The wiring diagram for this mode is shown on Fig. 3.7. If the
single-wire oxygen sensor is installed on your car, then the white wire from the
optimizer must be connected to ground. It is recommended, that during instruction
the oxygen sensor should be connected according to the standard scheme and the
optimizer should not be connected. To know more details about this mode, see
section 5.3;
2. The easiest method. The white wire from the optimizer must be connected to the
“minus” signal wire of the sensor, the red wire — to the “positive” signal wire (see
Figure 3.1). The red and white wires connected to the optimizer through a double
shielded cable
3. The more complex method is used in cases, when at first connection method the
engine is not stable even after a run of 100km. When you use this method of
connection, you should choose “offset” way to connect the oxygen sensor in the
optimizer program. To connect the optimizer under this method, you need to break
the signal wire of the oxygen sensor (see Fig. 3.2.). Connect the red wire of the
optimizer to the wire of oxygen sensor from ECU side, white one — to oxygen
sensor;
4. The most effective and accurate method of controlling the composition of the
mixture may be achieved only by means of a broadband oxygen sensor. Therefore,
we recommend installation of broadband oxygen sensor instead of zirconium
oxygen sensor; this allows to make the signal converter oxygen sensor SP-01. The
wiring diagram for this mode is shown in Fig. 3.6.;
5. There are two ways to connect broadband oxygen sensor sensor. Optimal one —
with control of mixture, simplified one — without control. (See Fig. 3.3., Fig. 3.4.).
If you don’t need to lean the mixture, but to enrich it, connect the oxygen sensor
according to the scheme shown in Fig. 3.5.;
6. If the oxygen sensor in your car is located after the catalytic converter, you can use
the function of catalyst emulator of the oxygen sensor No. 2. The scheme of
connection of the second zirconium oxygen sensor shown in Fig. 3.7. Don't forget
to include this option in the program optimizer;
7. Read everything about the mode of the channel of oxygen sensor “MAF(P)” in
section 5.4. below.
Figure 3.1. Connection diagram of the zirconium oxygen sensor
Figure 3.2. The second way to connect zirconium oxygen sensor “offset” (Recommended by
default).
Figure 3.3. Connection broadband oxygen sensor with mixture control
Figure 3.4. Simplified connection of the broadband oxygen sensor (Recommended by default).
Figure 3.5. Method of connection of broadband oxygen sensor for the enrichment of the mixture.
Figure 3.7. Diagram of connection of zirconium oxygen sensor located after the catalyst or in
the “emulator” mode
Figure 3.8. Connector pin array
3.2.
Connection to MAF, MAP
For maximum system efficiency it is necessary to connect the mass air flow sensor
(MAF). The diagram of connection of MAF to the signal wire is shown in Fig. 3.9. The MAF pin
map may differ from the one that shown in figure. The signal wire is determined by the voltage
as for vehicle weight. With the ignition on and the stopped engine, the voltage on this wire
should be about 1Volt. When the engine is started, the voltage should increase at pressing on the
gas pedal. In some models of engines may use MAF with frequency output - voltage on signal
wire of the sensor does not change significantly. If you have this MAF, you should choose the
type of MAF “Digital” in the settings of the optimizer.
Figure 3.9. Diagram of connection of mass air flow sensor (sensor wiring may be different).
Red
Black
MAF is critical to the load (it is property of ECU) on some cars (e.g. Mitsubishi Galant,
Outlander). We connect optimizer instead of the ECU. The circuits ensuring normal operation of
analog MAF (MAP) are provided for such sensor to work properly inside the optimizer. That is
why it is necessary to decide if these chains will be used on your car or not.
To resolve this question, it is necessary:
 break the signal wire from the MAF;
 switch the ignition on without starting the engine;
 measure the voltage between the signal wire of the MAF and the car weight;
 if the voltage on MAF (MAP) output is more than 2Volt — it is necessary to include the
load of MAF (MAP) in the settings of the optimizer (in the program) (see section 4.3.).
If you have a MAF with pulse output, start the engine and measure the frequency of pulses from
the MAF at idle and in heavy throttling (many digital multimeters have function of frequency
measurement) before connecting the optimizer. If the frequency exceeded the value of 1000Hz in
any mode, it should be noted in the setting “Frequency range of MAF (MAP) — more than 1
kHz” and the type of the sensor.
3.3.
Connection to Common Rail diesel engine
During connection to the diesel engine, the following sensors are used:
 Mass air flow;
 Fuel pressure;
 Cam shaft;
 Absolute pressure sensor may be installed instead of the fuel pressure sensor (not
recommended).
Figure 3.10. Diagram of wiring of the sensors on the diesel engine.
The diagram of wiring of the sensors on the diesel engine, which helps to save fuel, is
shown in Fig. 3.10. If you use this diagram, the indicators of the fuel pressure will be overstated
and as a result the ECU will reduce the pressure in the fuel rail. If the optimizer is installed for
power tuning, switch red and white wires, as it is shown in Fig. 3.10.
To connect to the sensors it is necessary to find the signal wire. The optimizer connected to
the break of signal wire of MAF (MAP) sensor and fuel pressure sensor. It is not necessary to
break crankshaft sensor wire.
Description of the setting process is given in Section 5.5.
4.
Connection to computer, software
The optimizer has a connector for connection to the COM port of a personal computer. If
your computer does not have a suitable connector, the optimizer can be connected to the USB
connector on the computer through the adapter (adapter) USB - COM (RS-232), which can be
purchased in a computer store.
If you use a USB - COM, the software may be started only after connection of the adapter
and installation of its drivers.
The optimizer is a standalone device, so the computer is needed only for configuration of
the optimizer.
4.1.
Requirements for personal computer
Computer requirements are defined depending on the functions of the optimizer program,
which determines the loading of the processor (CPU). The load of CPU mainly depends on the
parameters of graphs drawing on the screen (the period of the output of graph, graph type: 3D or
ordinary, the number of displayed parameters, the time of information displayed on the graph).
We can say: the denser the graph is, the more load of CPU will be. During first time it is
recommended to start system monitor along with the optimizer, it is started by simultaneously
pressing of Ctrl+Alt+Del keys (see Fig. 4.1.), this will allow to understand on which extent the
program is demanding as of your computer. If the load of the processor core is more than 75% (2
times less value - 38% will be displayed on a 2-core processor instead of 75%. see Fig. 4.1.),
we recommend to change the output options for graph (to increase the range of output values, to
use page by page graph output, to reduce the number of parameters, to refuse 3D graph, to
reduce the time of one page).
Minimum recommended requirements (page by page 30 sec/page, the output interval 0.2
s): 256Mb RAM / 10Gb HDD / CPU at 1.6 GHz.
Figure 4.1. Typical CPU load during graph recording
Zone of unstable operation.
CPU capacity is not enough. It is
necessary to change the output options
The program uses only one core.
The second core is not loaded.
Zone of stable operation.
During the record on the graph
CPU load increases.
50% load of CPU is displayed,
although the computer can no longer
cope and one core is 100% loaded.
4.2.
Examination of software
Software is supplied with the optimizer. The software allows to read and save the
parameters of the signals from the sensors in real time, to adjust the settings of the optimizer.
There is the possibility of visualization of parameters in the form of graphs and diagrams. Using
the correction “3D” mode, you can read, edit and record the correction table in the optimizer,
save them on your computer, create table samples.
In the lower part of the program there is the status bar, which displays the current state of
the program:
 model of connected optimizer;
 the state of the optimizer (connected, disconnected);
 type of oxygen sensors;
the progress of the reading, recording,
The program functions are switched with the help of the buttons located at the bottom of
the program:
 “Settings” — the basic settings of the optimizer;
 “Graph” — allows to view, record, save the current settings and values of the
signals from the sensors of the engine;
 “The surface of MAF" — 3-D graph and table of precise setting of the correction
level of MAF and absolute pressure sensor signals;
 “Surface oxygen sensor” — 3-D graph and table of precise setting of the
correction level of oxygen sensor signal in the “Optimizer” mode;
 “Plane of oxygen sensor” — graph and table of indicators of the fuel mixture in
the “Emulator” mode.
Table 4.1. The list of measured (shown on graph) parameters obtained from the optimizer in real
time.
O. No. Name of the parameter
Note
1
Fuel injection time
2
instantaneous fuel economy, liters/hour
3
amount of consumed fuel, liters
Is not displayed on graph
4
voltage from analog MAF(MAP), Volt
5
frequency from pulse MAF(MAP), Herz
6
frequency from pulse MAF(MAP) after
optimizer, Herz
7
current through the broadband oxygen sensor, Only with broadband oxygen sensor
mA
8
quality of the mixture, oxygen sensor
Only with broadband oxygen sensor
9
voltage from the oxygen sensor, Volt
Only for zirconium oxygen sensor
10
voltage from the oxygen sensor after
Only for zirconium oxygen sensor,
optimizer, Volt
method of connection — “offset”
11
rotational rate of crankshaft, rounds per
minute
Figure 4.2. The program window at the output on graph. Conclusion on graph.
Connect /
disconnect
optimizer
Scale based
on
parameter
Select
COM
port
Display on
graph on/off
Select the
color of the
graph
Read previously
saved data
Start
Stop
Scale
graph
grap
setting
Period of
update of the
graph
Width of
graph page
Save obtained data
“ oX range” switch
auto /page
The more detailed description of important program elements:
 Key of optimizer connection
To start working with the program you need to select the COM port and click on this key.
When you press this key, the program establishes connection with the emulator, reads its
settings. When you click “Connect module”, the connection of the Program with the
specified COM port is established. Upon successful connection, in the bottom of the
window you will see the blue line, elongating as the module data are read and text
“Module is connected”. If connection with the optimizer is absent during 5 seconds, you
will see the text “Connection failed”. You should check the entire connection chain and
try to establish the connection again. The program remembers used COM port. Key
“Disconnect the module – X” is optional, when you close the program, module
disconnects automatically.
 Window of selection of COM port
specifies for the program, to which
connector of the computer the optimizer is connected. Before you start to work with the
program, you should specify the COM port number, otherwise, the program wouldn’t be
able to establish connection with the optimizer.
 Period of graph update (the polling interval)/ It specifies the interval, with which the
data are shown on the graph. For example, “0,2” means that the values are displayed on
the graph with an interval of 0.2 seconds.
4.2.1. Output on the graph
The view of the window is shown on Fig. 4.2.
“Start / pause” the graph — is to start and temporary stop the graph. If key pause is
pressed, an expanded view of the graph is not available. Further clicking on the key “start”
continues the recording of the graph from the place of pause.
“Stop graph” — the graph is stopped for further viewing and saving. If you click this key,
then you will be able to start the graph again only after you clean it.
“clean the graph” — cleans the graph. After cleaning the graph, key “start” becomes
available.
The key “Continue graph”  — becomes active when the key “Pause” was pressed. Its
purpose is to continue the display on graph after pause.
The switch “continuously/page”. Its purpose is to choose the method of graphing. “Auto” - the
entire graph is fitted within the window, as new values are added, the graph is compressed.
“Pages” - the graph displays by fragments - pages.
The length of one page may be configured by the key. At the time when the page is already
recorded, the recording of a new page starts.
“Width of graph page, sec”. Its purpose is to choose an interval of one page from 5 to 120 sec
at a page-oriented output. Information on the selected width of the page is saved until the next
session.
The parameter “range of permitted deviations” affects filtering of data received from the
optimizer to minimize the display of possible false emissions on the graph. The degree of noise
filtering is a percentage of the maximum allowable emission on the graph for one period of the
survey of the optimizer. This means that the smaller the value of the allowed deviation is, the
higher the degree of filtering is. That is, if it is necessary to get a smoother graph, decrease of the
range value is needed. Information on the selected range is saved until the next session.
 — the purpose of this key is to save data obtained from the optimizer on your computer for
later viewing.
— the purpose of this key is to view previously saved data as a graph.
For convenience of your data research, the possibility is given to set limits on each of the two
vertical scales of values in your sole discretion.
There are three methods of vertical scaling:
I. “Auto” — the limits are automatically extended when values that do not fit into the
current range occur (for access, click “show scale”);
II. “Select limit” — the scale range is set by the user. The upper limit of the scale is set at
the top of the panel, the lower limit is set at the bottom (to access, click “show
scale”);
III. The range of the graph may be configured according to any of the options. To do this,
click on the white box next to the desired setting.
4.2.2. Window “Settings”
Figure 4.3. View of Window “Settings”
 Switch of mode selection of operation inputs (channels) of the oxygen sensor. Oxygen
sensor optimizer inputs can work in three modes: the Optimizer, the emulator, MAF(P).
The optimizer is the main operation mode (in this mode signals from sensors are
adjusted). Emulator — emulates the work of zirconium oxygen sensors on the basis of
data received from injector sensors, data of generated table of instruction, data of
consumption. The purpose of MAF(P) inputs is to connect the oxygen sensors, they can
be used to correct any signal from 0 to 5V.
 Coefficient of calculation the rotational rate of the crankshaft. The fuel nozzles can
inject fuel singly or in pairs depending on the injection scheme used on the car. This
affects the formula of calculation the rotational rate, in which this coefficient is
implemented. If the rotational rate is not displayed correct - correct this coefficient.
 Coefficient of calculation of fuel consumption. The optimizer does not know the exact
parameters of the fuel nozzles. Therefore, it is needed to specify this coefficient for
correct calculation of fuel consumption. Adjustment: Before you begin to set up the
coefficient, you need to ensure that the measurement coefficient is equal to 100, if not,
set the value to 100. Fill the tank with certain amount of fuel; use the fuel during the
riding process. Adjust the coefficient of fuel measurement. This value can be calculated:
Measurement coefficient 
100  Correct _ consumption
Indicators _ of _ consumption _ on _ ECU _ block
 Correction of the oxygen sensor. This is the correction coefficient of oxygen sensor at the
simple correction mode, which does not apply 3-dimensional tables. In this case, the
correction at idle is not performed. The degree of correction increases with increasing of
current fuel consumption (instantaneous) up to the one specified in this setting.
 Number of nozzles. Here you must specify the number of fuel nozzles. This option affects
the calculation of fuel consumption.
 Correction of MAF (MAP). This correction coefficient of MAF (MAP) at the simple
correction mode, which does not apply 3-dimensional tables. In this case, the correction
at idle is not performed. The degree of correction increases with increasing of current fuel
consumption (instantaneous) up to the one specified in this setting.
 Engine capacity. Specify engine capacity in liters. This parameter is used to calculate fuel
consumption.
 Threshold value U of analog MAF (MAP). The voltage value from the MAF (MAP), at
which the signal starts to be corrected. When the voltage value is smaller, the signal
passes through the optimizer unchanged. If the parameter “MAF (MAP)” is selected as
the reverse, the correction is made, if the voltage is less than the threshold (see Fig. 5.1.
below).
 Max U of oxygen sensor offset. Parameter is available only for zirconium oxygen sensor
if the selected scheme of connection is "offset". The optimizer is constructed so that
voltage of the oxygen sensor offset is as higher as the current consumption and the
correction coefficient, but not exceeding this parameter.
 Measurement voltage of offset as to the mass/input. The voltage of zirconium oxygen
sensor in the “offset” mode will be measured between mass and the red wire (output), or
between white and red wire (input and output).
 Method of connection of the oxygen sensor simple/offset. The parameter is available only
for a zirconium oxygen sensor. You must specify the connection diagram of oxygen
sensors (see Fig. 3.1., 3.2.)
 Use of channel of oxygen sensor No. 2. It allows to use the channel of the 2nd oxygen
sensor for emulation of the catalyst work through the 2nd oxygen sensor - to use this
function choose “catalyst”. If you need to adjust the parameters of the two oxygen sensor
located before the catalyst, choose the “normal” mode.
 Maximum correction point. Parameter is available only at the simple mode correction,
which does not apply 3-dimensional table. This is the point [rpm], after which the degree
of correction begins to decrease. This is especially useful when the optimizer is used in
conjunction with Braun gas generator and the current modulator. In this case, specify the
engine speed at which gas generation is at maximum (see Fig. 5.2. below).
 Correction decline level. The parameter is available only at the correction mode, which
does not apply 3-dimensional tables. This parameter determines how much the degree of
influence on the signals decreases at overcoming the threshold speed. If it is set to “1” —
correction decline level is minimal. If it is set to “8”, the level of correction is reduced
maximally after overcoming the threshold speed and its further increase. (See. Fig. 5.2.
below).
 Time of the delay in correction after switching on the ignition. The time from the moment
of switching on the ignition, during which the optimizer does not change signals.
 System on/off. Allows you to turn on /off the optimizer.
 Correction mode simple/3-D. At the correction mode “simple”, the correction is made
according to the following parameters: “Maximum correction point”, “Correction of
MAF (MAP)”, “Correction of oxygen sensor”. At the correction mode “3-D”, correction
is performed according to the tables of 3-D binding.
 Type of MAF (MAP) analog/digital. It is necessary to specify which MAF (MAP) is
installed on the car. The MAF (MAP) is considered to be analog, if its voltage varies
with changes in air consumption. The MAF (MAP) is considered to be digital (pulse), if
its signal on the output has pulse nature, i.e. the air consumption changes, the frequency
of the pulses from MAF (MAP) changes too.
 Frequency range of MAF (MAP) 1kHz / more than 1kHz. It indicates the frequency range
of digital (pulse) MAF (MAP). It is necessary to obtain the desired accuracy of the
frequency repetition at the output of the MAF (MAP). Change of this setting modifies the
way the signal correction. If the frequency of the signal at the output of the MAF (MAP)
does not exceed 1 kHz at any mode of operation of the motor – choose the range “up to
1kHz”.
 1kOhm Load of MAF (MAP) on /off. MAF (MAP) is critical to the load on some cars (e.g.
Mitsubishi Galant, Outlander). We connect optimizer instead of the ECU. For such
sensor to work properly inside the optimizer, circuits insuring normal operation of analog
MAF (MAP) are provided. When it is in “on” position, output of MAF (MAP) is loaded
on 1kOhm resistor. Whether to switch load of MAF (MAP) on or not is defined during
connection of the optimizer (see section 3).
 Character of MAF (MAP) direct/reverse. This parameter defines if the voltage of the
analog MAF (MAP) output increases or decreases when the air consumption increases. If
the voltage of MAF (MAP) output increases when the gas pedal is pressed - select
“direct” character
 Maximum degree of mixture leaning-out. The parameter is available only for the
broadband oxygen sensor, which is connected according to the scheme with the control
of mixture (see Fig. 3.3.). The parameter indicates the limit value (the ratio of air : fuel)
of fuel mixture leaning-out.
Table 4.2. The list of editable parameters and functions in the “settings” window, which affect
the operation of the device.
O.No. Name of parameter
1
Coefficient of calculation of fuel consumption
2
5
Coefficient of correction of the oxygen sensor
signal *
Coefficient of correction of the MAF (MAP)
signal *
Threshold correction value of analog MAF
(MAP), V
Number of nozzles, pcs
6
Engine capacity, l
7
Maximal permitted voltage of oxygen sensor
offset, Volt
Maximum correction point *, rpm
3
4
8
9
10
11
Coefficient of calculation rotational rate of the
crankshaft
Maximum degree of mixture leaning-out *, (the
ratio of air : fuel)
Correction on / off
Note
Parameter is necessary for calculation
of fuel consumption
Value of signal, up to which the
correction is not made
Parameter is necessary for calculation
of fuel consumption
Parameter is necessary for calculation
of fuel consumption
Only at “offset” way of starting
Point, after which the degree of
correction is decreasing
It is necessary for accurate
calculation of rotation rate
Only for broadband oxygen sensor
Switch the automobile to standard
operation mode
12
13
14
15
Method of connection of the oxygen sensor
simple/offset
Type of MAF (MAP) analog/digital (pulse)
Character of MAF (MAP) direct/reverse
16
Frequency range of MAF (MAP) 1kHz / more
than 1kHz
1kOm Load of MAF (MAP) on /off
17
Correction mode simple/3-D
18
Time of the delay in start of correction
19
Selection of the way of changing of parameter
“voltage of offset of zirconium oxygen sensor”
 as to mass or as to input
20
Selection of the way of application of oxygen
sensor No. 2  for first oxygen sensor or second
oxygen sensor (as catalyst emulator)
Level of decay in “simple” mode of correction
at exceeding of set rotation rate
21
See Fig. 3.2.
Defines, if voltage from MAF
(MAP) is decreasing or increasing
due to increased air consumption
Only for digital (pulse) MAF (MAP)
Loads output of MAF (MAP) on load
of 1 kOhm resistance
At 3D correction is performed on 3dimensional tables
After switching on the ignition,
during this time no changes are made
to the signal.
The voltage of zirconium oxygen
sensor at “offset” mode will be
measured between mass and red wire
or between white and red wires
Allows to use the channel of second
oxygen sensor for emulation of
catalyst work.
After exceeding of threshold value
of rotation rate, the degree of
influence on parameters is
decreasing
4.3.
First ignition
After installation of the optimizer, you must set initial parameters. For this:
 Start the program of the optimizer on the computer;
 Select the COM port (for example
) to which the optimizer is connected (if
you do not have COM port, use an adapter “USB to COM" - it can be bought in a
computer store);
 Switch on the ignition;
 Click the button
“connect the module” - at this the current settings will be read
from the optimizer;
 Open the “Settings” tab;
 Set the parameters: “type of MAF”, “zirconium oxygen sensor connection method”,
“frequency range of MAF”, “MAF load” (see. P. 3)





Start the engine;
The values of “oxygen sensor correction” and “MAF correction” set to “0”;
Set the parameters “number of nozzles”, “engine volume”;
Set the parameter “point of maximum correction” (when used with a Brown gas generator
– it is the rotating speed of crankshaft at which the gas production is maximum). When
using the 3D mode, it must be taken into account during the construction of the table;
5.
Setting of the optimizer
We recommend to carry out the installation and setting of the optimizer in stages. After
each stage, you need to test the car in different modes to identify possible errors in setting. At the
first stage you need to configure only the air flow sensor (MAF), at the second - the oxygen
sensors (oxygen sensor). You should start the second stage after connecting and setting the MAF
(MAP) sensor.
All parameters must be set according to the type and the connection scheme of sensors.
5.1.
Description of a simple and 3-D correction
The optimizer may operate in simple correction mode and 3-D correction. Switching the
correction mode may be made on the “Settings” tab. The degree of correction is calculated from
the arrival of each impulse from the nozzle relative to several parameters.
Some configuration parameters of the optimizer, which affect the calculation of the
correction degree, are common to the simple correction mode and 3-D correction mode:
 The coefficient for calculating the rotation speed of the crankshaft;
 Threshold value of voltage of analog MAF (see. Fig. 5.1 below).
 The maximum voltage of zirconium oxygen sensor offset (only for schemes
“offset”. See Fig. 3.2.);
 Start-up time after start of ignition;
 The maximum degree of mixture leaning-out (only for broadband oxygen sensor).
Figure 5.1. The dependence of the degree of influence on the signal from analog MAF from the
parameter value from “Threshold of U MAF analog”
5.1.1.
Simple correction mode
Description of the parameters affecting this mode, see in paragraph 4.2.8. - panel "B".
In simple mode, the optimizer continuously calculates the current degree of change of the
signal. The main parameters for calculating the degree of correction are: “correction (oxygen
sensor or MAF)”, “the point of maximum correction”, relative instantaneous fuel consumption
(fuel quantity per time unit). The higher the instantaneous consumption is, the more the
optimizer modifies signals from the sensors. If the rotation speed of crankshaft exceeds the
maximum correction point, the degree of correction will decrease with increasing of rotation
speed of crankshaft.
In this mode, the optimizer does not change the sensor signal at idle speed (if the speed is
less than 1200 rpm).
Correction level increases in direct proportion to the current amount of fuel up to the set
point of maximum correction. The degree of correction specified in the settings in simple mode
is achieved at about 2000 rpm and at the injection time 3,0 ms.
Figure 5.2. Change in the degree of correction in the “simple” mode depending on the
rotation speed and current fuel quantity.
Correction level
Point of maximum
correction = 2000 rev/min
Rotation speed
Fuel quantity
5.1.2. 3-D correction mode
In 3-D mode the degree of signal change is determined by three-dimensional table. The
table contains fixed values of the crankshaft rotating speed and the fuel injection time or voltage
from MAF – at option (see. p. 4.2.8. – panel “А”). Thus, the user can bind mode operation of the
engine (rotation speed, injection time, air flow) to a particular value of the correction signal.
Figure 5.3. Graphical view of the tables in the program’s
window.
It is possible to carry out correction of signal according to the rotational speed, the
injection time, the flow of air. Table of correction is built in the form of a matrix of 8x8.
Columns of the matrix always correspond to the rotation speed. Rows of the matrix correspond
to the time of fuel injection or air flow (voltage from the MAF). Selection of lines mode is
carried out with the help of the switch (see. Fig. 5.4.).
Optimizer program averages the correction level to neighboring points of the table, if the
injection time and rotation speed coincide not exactly with the table. Thus, it appears a “smooth”
recount of correction, if the rotation speed and injection time are between tabulated values.
The result of the correction is affected by the same parameters listed in P. 5.1.
Graphic tabulated data is displayed as 3-dimensional model, which is shown in Fig. 5.3.
For MAF, the table value of correction degree indicates how much the voltage from the
MAF with a given injection time and the rotation speed of the crankshaft will change. For
example, the value “-50” means that the voltage after passing of optimizer will decrease by about
0.5V. If values of voltages from MAF are close to the setting value “Threshold of U MAF
analog”, the optimizer can reduce their impact on the signal of MAF (see. Fig. 5.1.). If the
voltage from MAF is lower than the settings “Threshold of U MAF analog” (if setting type of
MAF (P) is selected as “direct”), the signal passes through the optimizer unchanged.
Figure. 5.4. Table with correction parameters.
For example, if the
rotation speed is within
the range from 1200 to
1600 rpm, injection
time - between 3.2 and
4.0 ms, the calculation
of correction value is
carried out by the
optimizer on four
nearest-points with
interpolation method,
which provides a
smooth transition
between the values of
the table.
Rotation speed of
crankshaft
Fuel injection time
Negative value –
leaning-out of mixture
Read table from the
optimizer
Record the table into
the optimizer
Open previously saved on PC table
Save table on PC
Selecting a method of correction.
If you select “Injection time”, then rows of the table correspond to the time of injection.
If you select “Voltage from MAF”, then the rows of the table correspond to the voltage on the MAF.
5.2. Setting the correct display of the fuel consumption
The optimizer does not know the exact parameters of the fuel nozzles. Therefore, for
correct calculation of fuel consumption, it is necessary to enter the coefficient of fuel
consumption calculation.
The calculation of fuel consumption is also affected by some input parameters: the number
of fuel nozzles, engine’s volume.
Adjustment: Before you begin to set up the coefficient, you need to ensure that the
measurement coefficient is equal to 100, if not, set the value to 100. Fill the tank with certain
amount of fuel; use the fuel during the riding process. Adjust the coefficient of fuel
measurement. This value can be calculated:
Measurement _ coefficient 
100  Correct _ consumption
Indicators _ of _ cunsumption _ on _ ECU _ block
Near the counter is a button with which you can reset the counter fuel consumption.
5.3. Mode of oxygen sensor “emulator” inputs
Mode of emulator works with the optimizer version V2 (shown in the left
corner of the program SD-04_v2). To select the mode in “Settings” tab, set the
“Mode of channel oxygen sensor” → “Emulator”.
This mode is used to reconstruct the signal of zirconium oxygen sensor
(even in it is absent). The data on the number of air entering the engine (e.g.
from MAF), the amount of injected fuel and the data obtained in the course of training are used
for recreation (emulation) of the signal. For obtaining of a given composition of the mixture,
these data are processed and displayed in the form of a oxygen sensor signal.
In the training mode, the optimizer generates a table of dependence of voltage MAF (the
amount of air) from the amount of injected fuel. After training, the table becomes editable and
you can adjust the composition of the fuel mixture.
If your vehicle has no MAF (MAP), you can use the signal from the absolute pressure
sensor. In this case, you need to specify the type of sensor “MAP” in the settings.
Mode “emulator” is compatible with the emulator mode of the catalytic converter (only for
channel oxygen sensor No. 2).
5.3.1. Training the emulator
To use the mode of emulator, it is needed first to train the optimizer. To do this, select the
channel oxygen sensor mode “emulator” in the “Settings” tab, then press the green button “start
training oxygen sensor”, which is located below. The training process takes about 3 hours and
stops automatically throughout the training time the indicator “correction” flashes. In the process
of training the correction signals, which come to the optimizer, is not performed.
For the most proper training, it is desirable that regular oxygen sensor was installed and
connected. If this is not possible, the result of training can be corrected manually.
During the training process, the optimizer must be disconnected from the oxygen sensor.
After the completion of the training process, operational oxygen sensor needs to be
disconnected, instead of it the optimizer is connected (if not already connected), as shown in fig.
3.7.
5.3.2. Configuring the emulator
The setup should begin after the completion of the training process. Before setting up you
need to remove the table formed by the optimizer in the training process. For this, on the tab
“oxygen sensor binding” press the button, after that on the screen will be drawn blue dots,
which determine dependence of voltage from MAF (the amount of air) from the fuel amount. It
is desirable to save the table, which has been read, on your computer. If on the curve, which was
obtained in the training process, there are overshoots, they need to be corrected with the help of
moving the dots, and then saved on the optimizer.
If you want to change the composition of the fuel-air mixture, move the dots up or down
see Fig. 5.6. If the point is moved up, it causes leaning out of mixture, if down – enrichment.
Warning: it is not recommended to change the position of dot more than 0,8V (on vertical
scale), it can cause the changeover of engine to emergency mode (the indicator “Check
engine” will lit).
For convenience, the color of the moved dots will change to green. Previous dot’s position
is displayed as a blue curve.
After carrying out the necessary correction, the table with obtained values has to be
recorded back into the optimizer. To do this, press the button
see. fig. 5.5.
If necessary, compare the obtained curve with the actual performance of the engine; press
the button “dots”. Yellow dots of the present mode of engine’s operation will appear and
disappear on the screen. To end the display of yellow dots, click “stop dots”.
Yellow dots should be placed on the curve. If they are a little to the side, you need to wait 5
minutes to let the ECU to adapt. If the points are on the side of the curve, then you have to press
the “Stop” and move the curve to the side of dots, save on the optimizer.
A sign of normal operation is the position of yellow dot on the curve and the voltage
fluctuation on oxygen sensor wires coming from the optimizer in the range of about 0.1 ... 0,9V.
It is desirable to control with the tester.
For best performance, it is desirable to use oxygen sensor emulation with 3-D correction
mode of MAF, to make estimated amount of air to coincide with the readings from the oxygen
sensors.
Figure. 5.5. The approximate form of the graph, which was obtained as a result of training.
Figure. 5.6. Points and curves displayed on the graph
yellow – current data; blue – recorded on the optimizer during the
training process; green – edited by the user.
of
the
emulator:
5.4. Mode of oxygen sensor “MAF(P)” inputs
This mode is used when there is a need to adjust multiple analog signals with a range of 0
... 5 Volt. In mode “MAF(P)”, channels of the oxygen sensor are used for the correction of
signals. Depending on the connection, these channels can increase the voltage or decrease it (see
Fig. 5.7.).
The level of impact on the signal in simple correction mode is determined by parameter
“oxygen sensor correction 1”, in 3-D mode it is determined by 3-dimensional oxygen sensor
table for two channels simultaneously. In 3-D table, value of correction “-50” corresponds to a
change in voltage between the input and output of approximately on 0.5 volts.
Figure 5.7. Connection of an analog signal to the input of oxygen sensor with a purpose to
decrease signal. To regulate upwards, input and output must be swapped.
5.5. Setting on diesel
Mode of work with a diesel is available on optimizers starting from
version V3 (shown in the left corner of the program«SD-04_v3»).
To select the mode, set “Mode channel oxygen sensor”
→ “MAF(P)” in the tab «settings».
Then set the parameter “Coefficient of crankshaft frequency calculation”
equal to the number of teeth on the crown, from which readings are taken by the crankshaft
sensor.
Select correction mode «3-D». Correction mode “Normal” will not work on diesel.
Select the tab “Tables”. Then set “correct the tables on
MAF” (see. fig. 5.8.).
Figure 5.8. Tables setting for diesel.
Table “oxygen sensor” is responsible for
the correction of signal from the fuel
pressure sensor.
Table “MAF” is responsible for the
correction on air flow sensor.
The columns correspond to the
rotational speed of the crankshaft
Rows of the table correspond to the
voltage from the MAF
You must set the correction on
“voltage from” MAF
Range of values of table “oxygen sensor” (which is responsible for the level of change of
the signal from the fuel pressure sensor) may range from 0 to -99. Value “-50” corresponds to
the signal change on 0.5 volts. Depending on the method of connecting of the fuel pressure
sensor, a signal change can increase or decrease the signal (see. Fig. 3.10.).
Range of values of correction table “MAF” (MAP) (which is responsible for the level of
signal change from air flow sensor) may range from -99 to 99. The signal from the MAF can be
adjusted both to the smaller and to the larger side.
6. Possible difficulties and their elimination
The main cause of problems during the installation and configuration of the optimizer is
wrong understanding of the material presented in this manual or not understanding of the work
of injection motor. Possible reasons and their solutions are listed in Table 6.1.
Table 6.1. Problems and ways of their solutions.
Problem
It does not
memorize
settings, the
graph is not
written
Possible reason
Solution
There is no
1.
If you use an adapter, check that the drivers are
communication
installed for it. Running the program must be done only
of the optimizer after connecting the adapter.
with the
2.
Probably the power is not received on the
computer
optimizer or the ignition is off.
3.
Did you forget to push the button
?
4.
If the connection to the computer and the optimizer
is set, then in the top of the program you should see the
model of the optimizer, such as: SD-04_v2.
5.
Wrong COM port is selected in the window (see.
Fig. 4.2).
6.
It is not advisable to feed a laptop though the car’s
network during the process of setting.
Remember, if there is a connection, in the moments
when you change settings on the computer, write graph
– indicator “Connection to PC” blinks on the optimizer
When
MAF
(MAP)
is
connected,
the
engine stalls or
works
intermittently
The wires
connected in a
wrong way
A common mistake – people confuse the blue wire with a
line and the blue one with a sign “+”. Change the wires
reversed.
The type of Determine the type of MAF and set the required values in
MAF (MAP) is the program
chosen wrong
For digital
signal
disappears
when connected
in the break of
the wire
On some cars, which use digital MAF (MAP), control
block “pulls” output of MAF (MAP) to +5volts. To
resolve this issue, you must install a special element inside
the optimizer. Consult your dealer about this.
Load MAF
Set the switch “Load MAF (MAP)” to the necessary
(MAP) is
enabled
mistakenly
position in accordance with p.3.2.
injection
time The blue wire is Reconnect the blue wire to the other wire of the nozzle.
and
rotational connected
speed are not wrong
displayed
Rotational speed Coefficient
is not displayed installed
correctly
incorrectly
Fuel
consumption
not displayed
Set the parameter “Coefficient of crankshaft’s rotational
speed”
The graph is not Fuel consumption is only updated when running graphs.
is written
Incorrect Font in
not Russian
language of
Windows or
incorrect
operation of
program
Russian fonts Open
are not installed Control Panel ->
Regional and language Options ->
Advanced.
Set “Language for non-Unicode Programs” in set
“Russian”
The
program No connection
displays a lot of with optimizer
unnecessary
elements
Upon successful connection, on the very top of the
program has to be displayed «SD-04v ...». If this does not
happen - you must check the correct choice of COM port
or reinstall the drivers for the adapter COM - USB.
The name of Pass to block the codes to correct alternately:
optimizer in its 3587)4497)
memory
is D2A7)03B7)
43C7)
damaged
The code is entered in the window next to the button
“transfer”, and then this button is pressed. Upon
successful completion from the optimizer will be a reply
“!”.
Then restart the program.
7. Warranty obligations
The manufacturer guarantees the performance of product subject to the rules of
exploitation set forth in the exploitation manual.
Warranty period of optimizer - 12 months from the date of sale.
During the warranty period of exploitation the owner, in case of failure of the system, has
the right to free repair.
During the warranty period of exploitation, the repair is accomplished at the expense of the
owner, if he does not use the optimizer in accordance with the exploitation manual, does not
follow the recommendations of the manufacturer.
The device is removed from the warranty in the following cases:
 If the device is opened;
 If there is mechanical damage;
 If the exploitation is not carried out in accordance with this user manual.
Optimizer SD-04, serial number ______ meets technical specifications and is considered suitable
for exploitation.
Release Date ________________ 2015.
Seller: ____________________________Stamp
Brand of car (in which the equipment is installed): _____________________
Mileage at the time of installation: ____________
Set by: ________________ / __________________________ /
Install Date: _____________
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